Vmac 9052 Installation guide

Installation Manual

For The

System #9052

UNDERHOOD AIR COMPRESSOR

1999-2000 FORD F250-F350

TRITON V8

TEL: 250-754-6997

FAX: 250-754-6972

TOLL FREE: 800-738-8622

1333 KIPP ROAD, NANAIMO, B.C. V9X 1R3

DOCUMENT 19472

Installation Manual

VR7000 Underhood Air Compressor

System Number 9052

Application: 1999-2000 Ford F250-F550 with the Triton V8

Publication Date: May 2000

Publication Number: 19472

Origination Documents: #19472a - introduction

#19473 - compressor and oil cooler installation

#19474 - air tank and line installation

#19475 - throttle controller installation

#19476 - control unit installation

#19478 - illustrated parts list

#19179 - warranty registration

Registered Trademarks:

VR7000, VMAC and Throttle Commander are registered trademarks of VMAC.

Ford, Super Duty, F250-F350, Power Stroke Diesel are registered trademarks of Ford Motor

Company

Loctite, Prime N’ Clean, 242 and PST are registered trademarks of Loctite Corporation.

Nylok is a registered trademark of Nylok Fastener Corporation.

Notice:

Manuals and products are subject to change without notice.

The contents of this manual may not be reproduced in any form without the express written

permission of VMAC

Contents

GENERAL INFORMATION................................................................................................ 3

INTRODUCTION ........................................................................................................................ 5

INSTALLATION NOTES .............................................................................................................. 6

ORDERING PARTS .................................................................................................................... 7

WARRANTY ............................................................................................................................. 7

CHANGES AND IMPROVEMENTS .................................................................................................. 7

PART 1: INSTALLING THE COMPRESSOR AND OIL COOLER ................................ 9

1.1 PREPARING FOR INSTALLATION .......................................................................................... 11

1.2 INSTALLING THE BRACKET ................................................................................................ 15

1.3 INSTALLING THE VR7000 COMPRESSOR AND OTHER COMPONENTS ......................................... 16

1.4 INSTALLING THE OIL COOLER AND ADAPTER ....................................................................... 18

PART 2: INSTALLING THE AIR TANK AND LINES ................................................... 21

2.1 INSTALLING THE BRACKETS AND TANK ............................................................................... 23

2.2 CONNECTING THE AIR AND OIL LINES ................................................................................ 27

2.3 ADDING OIL TO THE SYSTEM ............................................................................................ 29

2.4 COMPLETING THE INSTALLATION ...................................................................................... 30

PART 3: INSTALLING THE CONTROL UNIT ............................................................... 31

3.1 INSTALLING THE CONTROL UNIT ........................................................................................ 33

3.2 CONNECTING THE WIRING ................................................................................................ 34

PART 4: INSTALLING THE THROTTLE CONTROLLER ........................................... 39

4.1 INSTALLING THE THROTTLE CONTROLLER ASSEMBLY ........................................................... 41

4.2 INSTALLING AND ADJUSTING THE CABLE ............................................................................. 43

ILLUSTRATED PARTS LIST .............................................................................................. 47

WARRANTY REGISTRATION .......................................................................................... 53

1

2

General Information

System #9052

1999-2000 FORD F250-F350

TRITON V8

UNDERHOOD AIR COMPRESSOR

3

DOCUMENT 19472A

4

This symbol indicates that there is additional information or special emphasis

on a specific procedure.

This symbol indicates that there is a possibility of personal injury or damage to

the equipment if the indicated warning is not followed.

General Information

Introduction

This book provides installation instructions for:

VMAC underhood air compressor installation kit

VMAC Pneumatic Throttle Control

This kit has been designed for:

1999-2000 Ford F250-F350 equipped with a Triton V8

Installation steps

The installation procedure in this manual has four main steps:

Part 1: Installing the Compressor

Part 2: Installing the Oil Cooler, Air Tank and Lines

Part 3: Installing the Control Unit

Part 4: Installing the Pneumatic Throttle Control

Terms and symbols

This manual uses the following terms and symbols:

•OEM - Original Equipment Manufacturer

•HHCS - Hex Head Cap Screw (also called a hex bolt)

•SHCS - Socket Head Cap Screw (also called an Allen head bolt)

NOTE

WARNING

!

5

DOCUMENT 19472A

Installation Notes

1. It is important that you complete all the installation steps before operating the system.

2. Follow all safety precautions for under-hood mechanical work.

3. Use Loctite 242 or equivalent on all engine-mounted fasteners.

4. All hoses, tubes and wires which are re-routed or shifted during installation must be

secured so that they do not contact excessively hot areas or sharp edges. Where

possible, follow the routing instructions in this manual.

5. These installation instructions are intended as a general guide. In some instances, due

to variations in vehicle manufacture or if prior modifications have been made to the

vehicle, it may be necessary to carry out grinding, bending or rearranging operations

for correct fit. These operations must follow sound, standard shop practices.

6. Left and right definitions in this manual are determined when sitting in the driver’s

seat, facing forward.

7. All fasteners must be of the correct size and torqued according to the specifications

shown below. Torque specifications are in foot pounds (ft-lb).

6

T

y

pe Grade 8 plated Class 10.9 unplated

Size In Cast or

Steel

In

Aluminum

In Cast or

Steel

In

Aluminum

3/8 48 45

7/16 77 70

1/2 117 95

M8 25 20

M10 45 40

M12 80 70

M14 145 130

DOCUMENT 19472A

Ordering parts

To order parts, contact VMAC at:

Telephone 250-754-6997

Facsimile 250-754-6972

Office Hours 8:00 AM to 4:30 PM Pacific Time (Monday-Friday)

Please quote the VMAC part number, the description and the quantity.

Warranty

The VMAC warranty form is located at the back of this manual. This warranty form must be

completed and mailed or faxed to VMAC at the time of installation for any subsequent warranty

claim to be considered valid.

The enclosed System Identification Number Plate must be attached to the vehicle at the time of

installation.

Locate the plate on the front body support on the driver’s side of the vehicle near the hood stop

(Figure 1) . Drill the two hole locations using a 7/64 inch drill bit. Place the plate in position and fix

in place with the supplied #6 pan head self tapping screws.

IMPORTANT

The System Identification Number Plate provides information, which allows VMAC to assist in

customer inquiries and/or ordering of parts. It is important that this plate is affixed to the vehicle.

Figure 1 Location of System Identification Number Plate

Changes and improvements

These products and documents are subject to changes or improvements without notice.

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DOCUMENT 19472A

8

Part 1

Installing

the Compressor,

and Oil Cooler

System #9052

1999-2000 FORD F250-F350

TRITON V8

UNDERHOOD AIR COMPRESSOR

9

DOCUMENT 19473

10

Part 1: Installing the Compressor and Oil Cooler

1.1 Preparing for installation

1. Disconnect the batteries.

2. Disconnect the wiring from the alternator. Remove the alternator top support bracket and

the alternator from the engine.

3 Drain the coolant. Remove the top radiator hose.

4. Remove the OEM hose clamps from the radiator end of the lower hose, the water pump

end connecting the pump to the diverter and from the two (2) 3/4 inch hoses at the diverter.

5. Remove the two (2) 3/4 inch hoses from the diverter.

6. Disconnect the hose ends from the radiator and the pump and remove the assembly from

the vehicle (Figure 1.1).

7. Measure and mark 5 inches from the water pump end of the hose and cut at this mark.

Discard the cut end.

8. Measure and mark 3 inches from the diverter on the lower radiator hose and cut at this

mark. Discard the cut end.

9. Measure and mark 5-1/4 inches on the 3/4 inch hose nearest the driver’s side of the vehicle

and cut at this mark. Discard the cut end.

10. Measure and mark 5-3/4 inches on the other 3/4 inch hose and cut at this mark. Discard

the cut end.

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DOCUMENT 19473

5”

5-1/4”5-3/4”

3”

Discard this end

Figure 1.1 Modifying hoses

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DOCUMENT 19473

Left Bank

Right Bank

Remove This

Studded Hex

Head Cap Screw

OEM Belt Tensioner

OEM Back Idler

Figure 1.2 Location of OEM components

11. Place hose clamps over the 3/4 inch hoses and the hose to the water pump.

12. Install the diverter and hose assembly back into the vehicle. Tighten the hose clamps.

13. Remove the coolant expansion tank.

14. Remove the OEM drive belt and the engine cooling fan

15. Remove the OEM oil filler cap.

16. Push a clean rag into the plastic filler tube to catch cuttings.

17. Measure and mark the filler tube at the half-way point and cut the plastic filler tube off at this

mark. Remove the rag, making sure that no cuttings enter the engine.

18. Install the short, 45 degree rubber hose over the filler tube on the valve cover, positioning it

so that it points toward the passenger fender.

19. Place two (2) hose clamps over the tube.

20. Install the cut end of the filler tube into the top of the rubber hose. Tighten both hose clamps

and replace the filler cap.

21. Remove the OEM 10 mm bolt with the 8 mm studded end from the top right location on the

timing cover (Figure 1.2).

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DOCUMENT 19473

Figure 1.3 Grind off flashing from coolant manifold

Grind area shown within border

1. Remove the 3/4 inch heater supply hose from the manifold outlet tube and remove the tube

from the manifold using a puller or by inserting a snug-fitting cap screw into the fitting and

using visegrips. Apply sealant to the supplied 5/8 inch core plug and install it into the

manifold.

2. Loosen the cap screw holding the electrical connector to the intake manifold beside the

temperature sensor and rotate it 90 degrees counter clockwise. Tighten the cap

screw.

22. Make sure that the areas where the VR7000 bracket will mount are clean so that the

bracket will sit flush on the mounting areas. Place the VR7000 bracket in position and

make sure that it does not contact the coolant manifold. If necessary, grind off the casting

flashing to provide clearance (Figure 1.3).

3. Remove the OEM coolant temperature sending unit at the front of the inlet manifold next to

the thermostat housing.

4. Apply Loctite 592 sealant and install the supplied heater hose adapter block into the port of

the removed OEM coolant temperature transmitter. Tighten the adapter and make sure that

final alignment has the 1/2 inch hose barb facing approximately 45 degrees to the passenger

side from the engine center line (Figure 1.3).

5. Apply Loctite 592 to the hose barb and install it in the adapter block. Tighten the fitting.

6. Route the heater hose along the intake manifold between the intake runners for cylinder 1

and 3, to the hose barb (Figure 1.5). Install the hose on the hose barb at the adapter block

and make sure that the OEM hose clamp is in place.

INSTRUCTIONS FOR 2000 MODELS ONLY

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DOCUMENT 19473

Figure 1.5 Installing the adapter

Figure 1.4 Installing the core plug, routing and protecting the coolant line

7. Apply Loctite 592 sealant and install the OEM temperature sensor into the fitting in the hose

adapter block. Connect the electrical harness to the sensor.

8. Install the supplied protective loom material on the heater hose to prevent damage from

chafing.

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DOCUMENT 19473

1.2 Installing the bracket

1. Install the compressor mounting bracket to the engine as shown in Figure 1.6.

2. Apply Loctite, then install three (3) 10mm x 35mm socket head cap screws,

two (2) 8mm x 25mm hex head cap screws and one (1) 10mm x 100mm socket head cap

screws as shown in Figure 1.7.

Figure 1.6 Installation location for compressor mounting bracket

Left Bank

Right Bank

Three (3) 10mm x 35 mm

Socket Head Cap Screws

One (1) 10mm x 35 mm

Socket Head Cap Screw

Two (2) 8mm x 25mm Hex Head Cap Screws

Figure 1.7 Location of fasteners for the mounting bracket

1.3 Installing the VR7000 compressor and other components

1. Apply Loctite to the studs on the bottom of the compressor, position the compressor in

place on the VR7000 bracket, install the 8mm nuts and flat washers and torque to

specifications.

2. Install the alternator and connect the wiring. Some readjustment of the wire harness is

necessary.

3. Install the engine cooling fan along with the shroud.

4. Install the OEM serpentine belt according to the routing diagram in Figure 1.9.

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DOCUMENT 19473

VR7000 Belt Tensioner

VR7000 Back Idler

VR7000 Ribbed Idler

Figure 1.8 Location of idlers and tensioners

3. Tighten the fasteners until they are snug and then torque them to specifications

4. Remove the hex head cap screws from the back idler and the ribbed idler (Figure 1.8).

Apply Loctite to the fastener, install it and torque it to specifications.

5. Torque the Nylok fastener on the VR7000 belt tensioner to specifications.

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DOCUMENT 19473

5. Clean all dirt and contamination from the inside of the OEM crankshaft pulley.

6. Make sure that the threads in the three (3) 10mm holes are clean.

7. Place the VR7000 crankshaft pulley in place over the OEM pulley. Apply Loctite to the

three (3) 10mm x 60mm hex head cap screws and supplied flat washers and install them

into the holes in the OEM pulley. Torque the fasteners to specifications.

8. Install the VR7000 serpentine belt according to the routing diagram in Figure 1.10.

Crank

Pulley

Water

Pump

Alternator

Power Steering

Air Conditioning

Idler

Tensioner

Figure 1.9 Installation of OEM belt

Crank

Pulle

y

VR7000 Back Idler

VR7000 Compressor

VR7000 Tensioner

VR7000 Ribbed Idler

Figure 1.10 Installation of VR7000 belt

1.4 Installing the oil cooler and adapter

1. Remove the nuts on the studs securing the battery ground cable bracket to the lower engine

timing cover (Figure 1.12). Remove the battery ground cable from the stud. Discard the

battery ground cable bracket.

Figure 1.12 Removing the battery ground cable

OEM Battery Bracket And

Ground Strap Locations

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DOCUMENT 19473

9. Install the upper radiator hose.

10. Enlarge the mounting hole in the coolant expansion tank as shown in Figure 1.11, then

mount the expansion tank back in place.

Extend Hole 1/8”

Figure 1.11 Enlarge the mounting hole in the expansion tank

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Vmac 9052 Installation guide

Vmac 9052 Installation guide

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